J.s.t. Corporation

David Demaratos

Joshua Taylor

Franklin Anthony Holub

Frank Holub

Nathan Like

Rajit Abraham

The present invention involves a method for reducing the effect of electromagnetic interference (EMI) by providing EMI protection to a high voltage connector assembly, by employing a conductive outer housing, having a conductive tab or plurality of conductive tabs, the conductive outer housing also accommodating a seal (seal spring), a second outer housing, and a conductive third outer housing. The tabs being conductive coated to provide an element or portion of a grounding scheme for a connector assembly containing the outer housing. The conductive tabs make substantial contact with the conductive third outer housing and complete a portion of the connector assembly grounding scheme. The seal spring provides more force, additional force, for higher contact pressure with the third outer housing than would be present without the seal spring, resulting in better electrical conductivity between a conductive tab and the conductive third outer housing when in use.

Method for electromagnetic interference (EMI) protection for a high voltage connector assembly having a conductive outer housing, with at least a conductive tab, that accommodates therein a seal spring

The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within an outer housing and connector assembly. The seal spring compresses and provides adequate spring force against a tab or tabs within the outer housing. The seal spring also functions as an interface seal and an environmental seal during use. The seal spring is, substantially, in its entirety, of a contiguous and continuous single construction. No part or section of the seal spring is made up of welded, soldered, or brazen part or section.

Elastomer seal spring

The present invention involves an outer housing, having a tab or plurality of tabs, the housing accommodating a seal (seal spring), a second outer housing, and a third outer housing. The tabs being conductive coated to provide an element or portion of a grounding scheme for a connector assembly containing the outer housing. The tabs make substantial contact with the third outer housing and complete a portion of the connector assembly grounding scheme. When the outer housing is provided with a seal spring, the seal spring provides more force, additional force, for higher contact pressure with the third outer housing than would be present without the seal spring.

Outer housing, having at least a conductive tab, for accommodating therein a seal spring

The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within a conductive female housing and connector assembly. The seal spring compresses and provides adequate spring force against a disk ferrule assembly, pressing the disk ferrule assembly, with a wire shield, against a conductive female outer housing, providing a grounding scheme for the connector assembly. The seal spring also seals against the female outer housing and a wire.

A method for improving clearance and creepage in a male or female high voltage connector assembly using a male terminal position assurance (TPA) device. The high voltage connector assembly is suitable for high voltage electrical terminals. The method includes the steps of allowing a clearance and creepage or electrical path to extend from at least a high voltage electrical terminal to a conductive male outer housing, and or between another terminal using a male or a female TPA device. The TPA device is inserted in the high voltage connector assembly, whereby a clearance and creepage or electrical path extends from the high voltage electrical terminal along at least a surface of the TPA device and to the male outer housing of the high voltage connector assembly or from the high voltage electrical terminal to another high voltage electrical terminal in using the male and or female TPA device.

Method for improving clearance and creepage in a high voltage connector assembly using a male or female terminal position assurance (TPA) device

A manufacturing method for assembling a high voltage vertical disk ferrule, the ferrule being stamped and having a vertical disk-like structure, which is not necessarily round or does not necessarily have any roundness. The high voltage disk ferrule has an opening residing and traveling over the wire core and/or a wire braided shield, to which an end portion of the wire braided shield is affixed thereto the ferrule, or between two ferrules, such that a portion of the wire braided shield is flared and substantially perpendicular to the direction along which the wire core extends. The high voltage vertical disk ferrule slides over the core insulation, towards the outer insulation when the wire is pushed. The end portion/flared portion of the braided shield and the high voltage vertical disk ferrule, or the end portion/flared portion of the braided shield between at least two high voltage vertical disk ferrules are soldered, welded, or brazed together. The wire braided shield develops a natural spring force against the ferrule, and causes it to be accordioned, pleated, or folded against itself, and therefore pushes the vertical disk ferrule forward.

Manufacturing method for assembling at least a high voltage vertical disk ferrule

A high voltage vertical disk ferrule, and method for assembling thereof, the ferrule being stamped and having a vertical disk-like structure, which is not necessarily round or does not necessarily have any roundness. The high voltage vertical disk ferrule has an opening residing and traveling over the wire core and/or a wire braided shield, to which an end portion of the wire braided shield is affixed to the ferrule, or between two ferrules, such that a portion of the wire braided shield is flared and substantially perpendicular to the direction along which the wire core extends. The high voltage vertical disk slides over the core insulation, and towards the outer insulation when the wire is pushed. The wire braided shield develops a natural spring force against the ferrule, and causes it to be accordioned, pleated, or folded against itself, and therefore pushes the vertical disk ferrule forward.

High voltage vertical disk ferrule, and method for assembling thereof

A method for shielding and grounding a connector assembly from electromagnetic interference (EMI) including at least one of a step of directing the EMI to at least an electrically conducting seal, and a step of directing the EMI to at least a male/female joint stamped shield. The EMI, generated by, e.g., at least a battery cable assembly or the like, housed within at least a male connector assembly or a female connector assembly of the connector assembly, has a flow path that is conducted through at least the electrically conductive seal and the male/female joint stamped shield of the connector assembly.

Method for shielding and grounding a connector assembly from electromagnetic interference (EMI) using a male/female joint stamped shield and conductive seal

A high voltage connector assembly having improved female and male housings with a female terminal position assurance (TPA) device, and a method for improving clearance and creepage of the electrical path in the high voltage connector assembly. The female housing includes an intermediate upper portion having apertures for respectively receiving front downward extending members of frontward extending members of the female TPA device to finally lock high voltage electrical terminals in the female housing, and to place the female TPA device in a full-lock position inside the female housing. When fully assembled, the clearance and creepage of the electrical path in the high voltage connector assembly extends in a substantially vertical direction from the high voltage electrical terminals, and extends along a separator wall of the male housing and towards a rear portion of the female housing in a substantially horizontal direction across an intermediate upper portion of the female housing and into adjacent high voltage electrical terminals. Also, when in a full-lock position, the TPA device, in its entirety, resides outside of the female housing with the exception of the downward extending members in such a manner as to not require any part of the TPA device to enter the cavities that house the terminals while being assembled or while resting in a pre-lock position to allow the terminals to be substantially fully encapsulated in all directions by a continuous insulating material.

High voltage connector assembly having improved female and male housings with a female terminal position assurance (TPA) device, and an improved method for improving clearance and creepage in the high voltage connector assembly

A method for reducing the effect of electromagnetic interference (EMI), providing EMI protection to a connector assembly, using at least one vertical disk ferrule. The method includes steps of providing a flared portion, first portion, of a wire shield to at least a vertical disk ferrule, or affixing between two of said vertical disk ferrules. Further, one of a step of providing a ferrule having a face which contacts a metallic connector housing directly; or providing the flared portion of the wire shield which contacts said metallic connector housing directly; wherein said EMI is conducted from said metallic connector housing to said ferrule or flared portion, further conducting said EMI to said flared portion of the wire shield, further conducting said EMI through a second portion of said wire shield, further conducting said EMI to ground; said EMI being generated by at least the metallic connector housing.

Method for electromagnetic interference (EMI) protection for a high voltage connector assembly having a high voltage vertical disk ferrule

A sealing system and a method for sealing a metal fastener and members having dissimilar metals for a header connector or a connector device from electrolyte in an area where, in the header connector or the connector device, certain dissimilar metals may be in contact. The metal fastener and other adjoining or abutting dissimilar metals are sealed by a non-conductive seal from electrolyte, thereby protecting the metal fastener and the other adjoining or abutting dissimilar metals from galvanic corrosion and subsequently protecting the integrity of the header connector or the connector device.

System and method for sealing a metal fastener from electrolyte in an area of dissimilar metals

A method for improving clearance and creepage in a male high voltage connector assembly using a male terminal position assurance (TPA) device. The male high voltage connector assembly is highly suitable for high voltage electrical terminals, which are larger terminals. The method includes a step of allowing a clearance and creepage or electrical path to extend from at least a high voltage electrical terminal to a male outer housing of the high voltage connector assembly. When the TPA device is inserted and locked within a male inner housing of the high voltage connector assembly, the clearance and creepage or electrical path extends from the high voltage electrical terminal along at least a surface of the TPA device and to the male outer housing of the high voltage connector assembly. The male TPA device includes wing-like shape members with intermediate members that extend substantially and respectively downward from the wing-like shape members.

Method for improving clearance and creepage in a high voltage connector assembly using a male terminal position assurance (TPA) device

A connector position assurance (CPA) member for assuring the engagement of a first connector housing with a second connector housing. The CPA member includes terminals which can conduct electricity through a conductor in the second connector housing when the CPA member is at a full-lock position, due to a closed electrical circuit. The terminals of the CPA member cannot conduct electricity through the conductor in the second connector housing when the CPA member is at a pre-lock position due to an open electrical circuit.

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Wixom, MI, United States of America

David Demaratos